Furnace lining



June -1, 1937. J. KARMANoaKY FURNACE LINING Filed Oct. l, 1935 I-i-i-l @4417 ATTO R N EY5 Patented `iune 1, 1937 fNlED A'rares ATi-:NT Fries 2 v(Halma,

This invention relates to wall structures of furnaces, and more particularly to a form of refractory brick or block which may be used for lining such furnaces. l

5 It is an object of this invention to provide a refractory block or brick having a form such that when the blocks are laid in courses they will interlock with adjacent blocks; and as a further object, that such blocks will interlock not only with the l blocks in the same course, but also with blocks in adjoining other courses.

It is another object of the invention to provide a block having projections and recesses formed thereon which interlock with projections and l recesses of adjacently-disposed blocks and which is of such shape that it may be used for forming an arched roof, a curved floor, or `for forming a `straight side wall.

Other objects and various features of the invention will be more apparent from the following description and claims, which are to be read in connection with the accompanying drawing, in which Figure l is a sectional elevational view of a reverberatory furnace which may be lined with blocks of my invention.

Fig. 2 is a perspective view of one form of refractory block including my invention.

Fig; 3 is a front elevational view of a modified form of block similar to the block of Fig. 2.

Fig. 4 is a sectional view taken on the line 4 4 of Fig. 3.

Fig. 5 is a sectional view of the block of my 'invention taken on the line 5-5 of Fig. 3.

Fig. 6 is an elevational view of the block of Fig. 2.

Fig. 'l illustrates the manner in which blocks of the type shown in Fig. 6 may be laid to forma straight wall.

Fig. 8 is a plan view showing the relation of the blocks constituting the floor' of the furnace of Fig. i.

Fig. 9 is a perspective view of a modliled form of the block of Fig. 2. In general, furnaces of the type with which this invention is concernedcomprise side wallsV l5, a roof l 6 and a oor l1, all resting upon a suitable base. These wall structures, which term may be used to include the side wall, roof and floor, are necessarily lined with a refractory material, the

particular character of which is selected in accordance with the character of metal to be melted. In order to facilitate the process of lining and relining such furnaces, the wall structures are usually formed from a plurality of bricks, or

blocks, of the ydesired refractory material. The bricks of such wall structures are usually held in their proper assembled relationship by suitable ironwork comprising, for example, a plurality of angle iron bracest which are joined at their opposlte ends by buck stays 26, only one of which ishere shown. The buck stays are usually threaded at their opposite ends and are provided with nuts 2l which may be used to adjust the tension on the stays. Thus, any undue strain which is le placed upon the lorickwork, and the stays, may be relieved by a proper adjustment of the nuts 2l. When the furnace is constructed in this manner, and more particularly when the floor on which the molten metal lies is formed from a plurality 15 of blocks, itis evident that the molten metal will f tend to seep into the joints between the blocks; and this seepage, of course. causes the oor to grow" or buckle. The resulting stresses are transmitted to the side walls and frequently cause 20 considerable damage. I have found that this seepage may be avoided, or very .materially reduced, by forming the wall structures from blocks which interlock with each other in such manner that the interlocking elements constitute a plu` .25 rality of obstructions to the flow of metal through the joints that is, each joint becomes, in effect, a labyrinth-like passage.

A preferred form of block, generally designated by the numeral i8 is shown in Fig. 2 and com- 30 prises, in effect, a series of integrally formed substantially rectangular sections which are ldisposed in overlapping relationship. For the purpose of description, the cross-sectional area of the block, per se, may be defined by the surface :r or 3;, by the cross-hatched section of Fig. 5. In the light of this definition it then appears that the offset sections I9 provide a plurality of projections 2li and alike number of recesses 2l. As can best` be seen in Figs. 2 and 5, the projections 20 may 40 be regarded as being formed on two adjacent faces of the block, whereas the recesses 2l are formed on the remaining two faces; and the projections and recesses lie in planes which are disposed at right angles to the longitudinal extent of the 45 block. The dimensions of the projections and recesses, including the length, are-substantially similar. Thus when the blocks are laid in courses,

` as shown in Fig. 8, a portion ofthe projection 20 of one block will llt into a portion of the recess 2l 50 of a block in the same course; and also with a portion of the recess 2l in a^-block in another course. This arrangement of-the recesses and projections permits the use of only one design for all of the blocks; and further, it permits a com- 55 plete interlocking between the blocks. This latter feature can best be understood by an examination of block I8a of Fig. 8, which will disclose that the projection 20a. and the recess 2 I a of block I la interlock with the complementary parts of adjacent blocks without leaving any cut-out corner portions.

While the blocks may be laid in any desired relationship, I prefer to utilize an overlapping masonry bond, l. e., with the blocks of one course overlapping the joints Iof blocks in adjacent courses. Where the blocks are so laid. it becomes substantially impossible to find any point at which a joint extends through the wall structure without encountering one of the projections. Thus, at any point of abutment between any two adjacent blocks it will be found that the joint therebetween is of labyrinth-like character.

As was previously mentioned, certain of the wall structures, namely, the floor and roof of the fur nace. are preferably curved. In order to obtain this curvature, I preferably provide a block which has a slight longitudinal taper whereby one end 22 is somewhat larger than the other end 7,3. 1n-

forming the concave floor surface the blocks are laid soldier fashion, that is, upon their ends, with the large end 22 resting upon afsuitable base 26, which preferably is made of an impervious material; and in overlapping` courses as shown in Fig. 8. The formation of the oor from tapered blocks, in effect, produces an inverted arch. It is` quite evident that. these same blocks' may be used for forming the arched roof it of the -furnace shown in Flg..l. Here the blocks are disposed with their' large ends .22 uppermost andtheir smaller ends constituting the inner surface of the furnace.

Th'e blocks of Figs. l and 6, having a taper on two sides only, are not only useful in forming the curved roof and floor structures but they may also be used to form the straight side walls l5. To

' accomplish this, the blocks are laid, as shown in of one block adjoinf Fig. 7, with the large end 22 ing the small end 23 of an adjacent block, the

' blocks being laid in courses which overlap along the short side of the` block, rather than the long side. Thus, a brick of a single shape may be used for forming the entire wail structure. Preferably, however, the side walls I5 are formed from straight-sided blocks, as shown in Fig. l. These blocks (Figs. 3, 4, and 5) are similar in all respects to the blocks of Figs. 2, 6, and 7, except that their opposite sides are parallel and at right angles to their ends.

The straight-sided blocks of Fig. 3 are not only useful in forming straight walls but they may be arched floors and roofs of different curvatures. Thus, wall structures of varying size, shape and curvature may bemade from only two shapes of brick.

As shown in Fig.' 1, the roof I6 and the floor I1 are concave in only one riirection; that is, they each comprise a segment of a cylinder. Hence, these structures are formed from blocks which have two opposite parallel sides, and two opposite tapered sides, as shown in Figs. 2 and 6. However, it it is desired to make them concave in all directions, i. e., each a section of a sphere, this may readily be done by tapering the four sides of ,the block, as shown in Fig. 9.

From the foregoing it is apparent that the blocks of my invention, irrespective of their shape, i. e.,'tapered or straight-sided, provide a complete interlock' at several points along each abutting face 0f adjacent blocks, and that each joint between adjacent blocksbecomes, in eect, a labylilithlike passage which tends to restrict and retard the leakage of molten metal therethrough.

Since certain changes may be made in the positioning of the projections and of the recesses, and since the block may be m'odied in other ways, several of which have here been shown and described, it is apparent that the invention is subjectv to modification without in any way departing `from the true scope thereof, and therefore it is intended that the foregoing description shall be construed in an illustrative rather than in a limiting sense.

What I claim is:

1..' A block of the character described, comprising an elongated body portion, spaced small and large projections extending transversely of the longitudinal side faces of the body portion defining alternate recesses ,in the side faces with small projections `and small recesses at the ends and with at least two transverse projections and two transverse recesses being` spaced inwardly of the ends of the block and in the same transverse zone and of greater width than the remaining projec- .tions and recesses, with each of the two wider recesses adapted to receive two complete projections at adjacent ends of two associated interlocked blocks.

2. A block of the character described in claim 1, characterized by the block having a transverse projection at each end of two adjacent side faces thereof and a recess at each end of two other adjacent side faces.

JOSEPH KARMANOCKY. 

